Mitsubishi Montero (2004+). Manual - part 385

INTAKE MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-11

>>D<< INTAKE MANIFOLD PLENUM GASKET 
INSTALLATION
Install the gasket with the protrusion in the position illustrated.

INSPECTION

M1151003100467

Check the following points; replace the part if a problem is 
found.

.

Intake Manifold Check
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port, or 

clogging of the exhaust gas recirculation passages.

3. Using a straight edge and feeler gauge, check for distortion 

of the cylinder head installation surface.

Standard value: 0.15 mm (0.006 inch) or less 
Limit: 0.20 mm (0.008 inch)

AC204098

FRONT

PROTRUSION

AB

EXHAUST MANIFOLD

TSB Revision

INTAKE AND EXHAUST

15-12

EXHAUST MANIFOLD

REMOVAL AND INSTALLATION

M1151003300416

INSPECTION

M1151003400402

Check the following points; replace the part if a problem is 
found.

.

Exhaust Manifold Check
1. Check for damage or cracking of any part.
2. Using a straight edge and a feeler gauge, check for 

distortion of the cylinder head installation surface.

Pre-removal and Post-installation Operation
• Front Exhaust Pipe Removal and Installation (Refer to 

P.15-13

.)

• Air Cleaner Removal and Installation (Refer to 

P.15-6

.)

• Battery and Battery Tray Removal and Installation

AC204049

1

2

3

4

5

6

7

14 ± 1 N·m
120 ± 13 in-lb

14 ± 1 N·m
120 ± 13 in-lb

44 ± 5 N·m
33 ± 3 ft-lb

18 ± 2 N·m
13 ± 2 ft-lb

N

N

N

59 ± 10 N·m
44 ± 7 ft-lb

44 ± 5 N·m
33 ± 3 ft-lb

8

9

10

14 ± 1 N·m
120 ± 13 in-lb

24 ± 4 N·m
18 ± 3 ft-lb

44 ± 8 N·m
33 ± 5 ft-lb

AB

REMOVAL STEPS

1. EGR PIPE
2. EGR PIPE GASKET
3. HEAT PROTECTOR <RH>
4. EXHAUST MANIFOLD <RH>
5. EXHAUST MANIFOLD GASKET 

<RH>

6. ENGINE OIL DIPSTICK GUIDE

7. TRANSMISSION FLUID  DIPSTICK 

GUIDE

8. HEAT PROTECTOR <LH>
9. EXHAUST MANIFOLD <LH>
10. EXHAUST MANIFOLD GASKET 

<LH>

REMOVAL STEPS (Continued)

EXHAUST PIPE AND MAIN MUFFLER

TSB Revision

INTAKE AND EXHAUST

15-13

Standard value: 0.15 mm (0.006 inch) or less 
Limit: 0.20 mm (0.008 inch)

EXHAUST PIPE AND MAIN MUFFLER

REMOVAL AND INSTALLATION

M1151008700152

Required Special Tool:

• MD998770: Oxygen sensor wrench

Pre-removal and Post-installation Operation
Front Under Cover Removal and Installation

AC204061

49 ± 10 N·m
37 ± 7 ft-lb

49 ± 4 N·m
37 ± 3 ft-lb

49 ± 10 N·m
37 ± 7 ft-lb

25 ± 4 N·m
18 ± 3 ft-lb

49 ± 10 N·m
37 ± 7 ft-lb

9.0 ± 2.0 N·m
79 ± 18 in-lb

49 ± 10 N·m
37 ± 7 ft-lb

13 ± 2 N·m
111 ± 22 in-lb

44 ± 5 N·m
33 ± 3 ft-lb

13 ± 2 N·m
111 ± 22 in-lb

13 ± 2 N·m
111 ± 22 in-lb

13 ± 2 N·m
111 ± 22 in-lb

49 ± 10 N·m
37 ± 7 ft-lb

8,10,11,12

2,6

8

9

17

12

11

14

13

10

15

18

6

7

5

6

6

16

1

3

2

2

4

3

N

N

N

N

N

AB

TAIL PIPE REMOVAL STEPS

1. TAIL PIPE
2. HANGER
3. HANGER BRACKET
4. REAR FLOOR HEAT PROTECTOR

MAIN MUFFLER REMOVAL STEPS

5. MAIN MUFFLER
6. HANGER
7. HANGER BRACKET

FRONT EXHAUST PIPE REMOVAL 
STEPS

<<A>> >>A<<

8. RIGHT BANK HEATED OXYGEN 

SENSOR (FRONT)

9. FRONT EXHAUST PIPE

<<A>> >>A<<

10. RIGHT BANK HEATED OXYGEN 

SENSOR (REAR)

<<A>> >>A<<

11. LEFT BANK HEATED OXYGEN 

SENSOR (REAR)

<<A>> >>A<<

12. LEFT BANK HEATED OXYGEN 

SENSOR (FRONT)

13. WARM-UP THREE-WAY CATALYTIC 

CONVERTER

14. BRACKET
15. SEAL RING
16. CATALYTIC CONVERTER
17. DASH HEAT PROTECTOR
18. FRONT FLOOR HEAT PROTECTOR

FRONT EXHAUST PIPE REMOVAL 
STEPS (Continued)

EXHAUST PIPE AND MAIN MUFFLER

TSB Revision

INTAKE AND EXHAUST

15-14

REMOVAL SERVICE POINT

.

<<A>>RIGHT BANK HEATED OXYGEN SENSOR 
(FRONT)/RIGHT BANK HEATED OXYGEN SENSOR 
(REAR)/LEFT BANK HEATED OXYGEN SENSOR 
(REAR)/LEFT BANK HEATED OXYGEN SENSOR (FRONT) 
REMOVAL
Use special tool MD998770 to remove the oxygen sensor.

INSTALLATION SERVICE POINT

.

>>A<< LEFT BANK HEATED OXYGEN SENSOR 
(FRONT)/LEFT BANK HEATED OXYGEN SENSOR 
(REAR)/RIGHT BANK HEATED OXYGEN SENSOR 
(REAR)/RIGHT BANK HEATED OXYGEN SENSOR (FRONT) 
INSTALLATION
Use special tool MD998770 to install the oxygen sensor.

ACX02426 AB

MD998770

ACX02426 AB

MD998770